US7954354B2 - Method of manufacturing containers - Google Patents
Method of manufacturing containers Download PDFInfo
- Publication number
- US7954354B2 US7954354B2 US11/768,267 US76826707A US7954354B2 US 7954354 B2 US7954354 B2 US 7954354B2 US 76826707 A US76826707 A US 76826707A US 7954354 B2 US7954354 B2 US 7954354B2
- Authority
- US
- United States
- Prior art keywords
- container
- diameter
- die
- sidewall
- lower body
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D51/00—Making hollow objects
- B21D51/16—Making hollow objects characterised by the use of the objects
- B21D51/26—Making hollow objects characterised by the use of the objects cans or tins; Closing same in a permanent manner
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D51/00—Making hollow objects
- B21D51/16—Making hollow objects characterised by the use of the objects
- B21D51/26—Making hollow objects characterised by the use of the objects cans or tins; Closing same in a permanent manner
- B21D51/2646—Of particular non cylindrical shape, e.g. conical, rectangular, polygonal, bulged
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
- B21D22/02—Stamping using rigid devices or tools
- B21D22/025—Stamping using rigid devices or tools for tubular articles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D37/00—Tools as parts of machines covered by this subclass
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D39/00—Application of procedures in order to connect objects or parts, e.g. coating with sheet metal otherwise than by plating; Tube expanders
- B21D39/08—Tube expanders
- B21D39/20—Tube expanders with mandrels, e.g. expandable
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D1/00—Containers having bodies formed in one piece, e.g. by casting metallic material, by moulding plastics, by blowing vitreous material, by throwing ceramic material, by moulding pulped fibrous material, by deep-drawing operations performed on sheet material
- B65D1/12—Cans, casks, barrels, or drums
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10S72/00—Metal deforming
- Y10S72/715—Method of making can bodies
Definitions
- substantially identically shaped beverage containers are produced massively and relatively economically.
- a method for manufacturing a container comprising: providing a container having a diameter X; and expanding the diameter of the container to Y with at least one expansion die is disclosed.
- Y is more than 8% greater than X.
- the container wall is substantially straight.
- the diameter Y of the container wall is substantially uniform.
- an end of the container is formed to accept a closure.
- the diameter of the wall proximate to the end of the container is narrowed to W.
- the narrowing of the wall comprises die necking.
- the die necking is performed without a knockout. In other embodiments, a knockout can be used.
- expanding the diameter of the container with at least one expansion die comprises expanding the diameter of the container with multiple expansion dies.
- the method for manufacturing further comprising expanding the diameter of the container to Z.
- Z is more than 20% greater than X.
- expanding the diameter of the container is part of an automated process.
- FIG. 1 is a perspective view of one embodiment of an expansion die used to expand a 2.087′′ diameter container to a 2.247′′ diameter container, in accordance with one embodiment of the present invention
- FIG. 2 is a top view of the expansion die of FIG. 1 showing line A-A;
- FIG. 3 is a cross-sectional view of the expansion die of FIGS. 1 and 2 along line A-A;
- FIG. 4 is a cross-sectional view of an expansion die used to expand a 2.247′′ diameter container to a 2.363′′ diameter container according to one embodiment of the invention
- FIG. 5 is a cross-sectional view of an expansion die which can be used to expand a 2.363′′ diameter container to a 2.479′′ diameter container;
- FIG. 6 is a cross-sectional view of an expansion die which can be used to expand a 2.479′′ diameter container to a 2.595′′ diameter container;
- FIG. 7 is a cross-sectional view of a lower body profile-setting die
- FIG. 8 is a side view of five containers, wherein each consecutive container represents one stage of expansion of a 2.087′′ diameter container to a 2.595′′ diameter container according to one embodiment of the invention
- FIG. 9 is a top view of the five containers of FIG. 8 ;
- FIG. 10 is a bottom view of the five containers of FIG. 8 ;
- FIG. 11 is a perspective view of a container base holder
- FIG. 12 is a top view of the container base holder of FIG. 11 , showing line A-A;
- FIG. 13 is a cross-sectional view along line A-A of the container base holder of FIGS. 11 and 12 ;
- FIG. 14 is a perspective view of a second container base holder
- FIG. 15 is a top view of the container base holder of FIG. 14 , showing line A-A;
- FIG. 16 is a cross-sectional view along line A-A of the container base holder of FIGS. 14 and 15 .
- a method of manufacturing a container comprises providing a container having a diameter X and expanding the diameter of the container to Y with at least one expansion die. In some embodiments, the container is further expanded to a diameter Z with at least one other expansion die.
- Embodiments of the invention may be used in conjunction with any container capable of being expanded including but not limited to beverage, aerosol, and food containers.
- the container provided may be manufactured via any suitable means, including, but not limited to, drawing, draw reverse draw, drawing and ironing, drawing and stretching, deep drawing, 2-piece seamed and impact extrusion.
- the container is comprised of aluminum or steel.
- the aluminum comprises an alloy, such as Aluminum Association 3104, 3004, 5042, 1060, 1070, steel alloys may also be used.
- the alloy has a hard temper, such as H19 or H39. In other embodiments, a softer temper metal is used.
- At least one expansion die 5 is inserted into an open end of the container to expand the diameter of the container from X to Y.
- Another expansion die can be inserted into the open end of the container to expand the diameter of the container from Y to Z. This process can be repeated until the desired container diameter is achieved.
- FIGS. 3-6 show a set of expansion dies used to expand a 2.087′′ diameter container to a 2.595′′ diameter container. The four stages of expansion of the container can be seen in FIGS. 8-10 .
- a gradual expansion of a container comprised of a hard temper alloy using multiple expansion dies of increasing diameters, as opposed to using one expansion die, allows the diameter of the container to be expanded up to about 25% without fracturing, wrinkling, buckling or otherwise damaging the metal comprising the container 70 .
- the number of expansion dies 5 used to expand a container 70 to a desired diameter without significantly damaging the container is dependent on the degree of expansion desired, the material of the container, the hardness of the material of the container, and the sidewall thickness of the container. For example, the higher the degree of expansion desired, the larger the number of expansion dies required.
- the metal comprising the container has a hard temper
- a larger number of expansion dies will be required as compared to expanding a container comprised of a softer metal the same degree.
- the thinner the sidewall 80 the greater number of expansion dies will be required.
- Progressive expansion using a series of expansion dies may provide increases in the container's 70 diameter on the order of 25%, wherein greater expansions have been contemplated, so long as the metal is not significantly damaged during expansion.
- the diameter of the container 70 is expanded more than 8%.
- the diameter of the container is expanded less than 8%, greater than 10%, greater than 15%, greater than 20%, greater than 25%, or greater than 40%. Other percentages of expansion are contemplated and are within the scope of some embodiments of the invention.
- a container may be expanded before coating.
- the method of forming a container 70 further includes forming the open end of the container to accept a closure.
- Forming the open end of the container 70 to accept a closure can comprise narrowing the diameter of the sidewall 80 proximate to the open end of the container to W.
- the diameter W may be less than, equal to, or greater than diameter X.
- the narrowing can be accomplished via die necking, spin necking or any suitable method.
- forming the open end of the container to accept a closure does not include narrowing the diameter of the sidewall.
- the necking process is accomplished using at least one necking die. Any suitable necking die known in the art may be used.
- the container 70 is necked to form a beverage can. In another embodiment the container 70 is necked to form a beverage container having a bottle shape.
- Necking all expanded container 70 formed in accordance with some embodiments of the invention to a diameter greater than or equal to the container's original diameter X does not require the use of a knockout because the container's sidewall 80 is in a state of tension following expansion.
- a knockout can be used when necking the container.
- the sidewall 80 of the container 70 is substantially straight meaning the sidewall has no curves and is substantially uniform in diameter.
- the sidewall 80 is defined as the wall of the container 70 between the lower body area 90 and the necked in portion of the container, or, if the container is not necked in, between the lower body area 90 and the top 95 of the container.
- the container is not necked in or otherwise narrowed.
- a top portion of the container 70 is necked in to accept a closure.
- the sidewall is substantially straight and of a substantially uniform diameter, but not completely straight or uniform in diameter, because the thickness of the metal comprising the sidewall may vary.
- the sidewall 80 may be curved and the container 70 may have varying diameters.
- the open end of the container 70 is formed to accept a closure.
- the forming step for attaching a closure to the open end of the container may be any known process or method, including, but not limited to, forming a flange, curl, thread, lug, attach an outsert and hem, or combinations thereof.
- Any suitable closure may be used, including but not limited to, standard double-seamed end, full-panel easy-open food end, crown closure, plastic threaded closure, roll-on pilfer proof closure, lug cap, aerosol valve, or crimp closure.
- the die is comprised of A2 tool steel, 58-60 Rc harden, 32 finish, although any suitable die material may be used.
- the expansion die 5 includes a work surface 10 , having a progressively expanding portion 15 , a land portion 20 , and a tapered portion 25 transitioning to an undercut portion 35 .
- An initial portion 30 of the work surface 10 in the depicted embodiment has a geometry for gradually transitioning the diameter of the container 70 sidewall 80 .
- the progressively expanding portion 15 has dimensions and a geometry that when inserted into the open end of a container 70 works the container's sidewall 80 to radially expand the container's diameter in a progressive manner as the container travels along the work surface 10 .
- the expansion die 5 provides the appropriate expansion and forming operations without the need of a knockout or like structure. In some embodiments, a knockout may be used.
- the land portion 20 has dimensions and a geometry for setting the final diameter of the container being formed by that expansion die 5 .
- the tapered portion 25 transitions from the land portion 20 to the undercut portion 35 .
- the undercut portion 35 extending at least the length of the container being expanded to enable the die to maintain control of the metal as it expands and to minimize the container becoming out-of-round. It is noted that the dimensions for the land portion 20 , the undercut portion 35 , and the tapered portion 25 are provided for illustrative purposes only and are not deemed to limit the invention, since other dimensions for the land portion 20 have also been contemplated and are within the scope of the disclosure.
- the work surface 10 may be a polished surface or a non-polished surface.
- a polished surface has a surface roughness average (Ra) finish ranging from 2 ⁇ in to 6 ⁇ in.
- the work surface 10 may be a non-polished surface having a surface roughness average (Ra) finish ranging from more than or equal to 8 ⁇ in to less than or equal to 32 ⁇ in, so long as the non-polished work surface 10 does not significantly degrade the product side coating disposed along the container's inner surface.
- the undercut portion 35 is a non-polished surface having a surface roughness average (Ra) finish ranging from more than or equal to 8 ⁇ in to less than or equal to 32 ⁇ in.
- the undercut portion 35 may extend into the expansion die wall by a dimension L of at least 0.005 inches preferably at least 0.015 inches. It is noted that the dimensions and surface roughness values for the undercut portion 35 are for illustrative purposes only and that the present invention is not deemed to be limited thereto.
- a die system for producing containers including the expansion die 5 .
- the die system includes at least a first expansion die 5 having a work surface 10 configured to increase a container's diameter, and at least one progressive expansion die, wherein each successive die in the series of progressive expansion dies has a work surface configured to provide an increasing degree of expansion in the container's diameter from the previous expansion die.
- the die system may also include one or more necking dies.
- the die system may also include a container base holder 100 .
- the container 70 may sit on the base holder 100 during the expansion operation.
- the profile of the base holder is designed to support the outside nose radius of the container and/or the lower body 90 area of the container 70 .
- the container base holder 100 shown in FIGS. 11-13 may be used during all stages of expansion of the containers shown in FIGS. 8-10 .
- the container base holder 110 shown in FIGS. 14-16 is an example of a base holder that may be used to expand a container comprised of a thinner metal, in some embodiments.
- a different base holder may be used during each stage of expansion as the holder is more tailored to the final expansion diameter of each stage of expansion.
- the expansion of the diameter of the container could take place as part of the automated, in-line container making process.
- the method of manufacturing a container 70 may not require changes to the cupper tooling and possibly no changes to the bodymaker tooling. Ironing ring changes may be required depending on the sidewall 80 requirements of the finished container.
- the necking process can be achieved without the use of knockouts due to the pre-stress in the container from expansion.
- a 204, 206 211 or 300 diameter container could be made using cupper and bodymaking tooling configured to manufacture a 202 container and one or more expansion dies.
- some embodiments of the invention eliminate the need to purchase additional expensive cupper and bodymaking tooling in order to create containers having different final diameters.
- an unexpanded container may be a perform.
- the four expansion dies depicted in FIGS. 3-6 are utilized to increase the internal diameter of the container 70 from about 2.087′′ to a diameter of about 2.595′′, as depicted in FIGS. 8-10 .
- the expansion die 5 depicted in FIGS. 1-3 can be used to expand the 2.087′′ diameter container to a 2.247′′ diameter container.
- the expansion die shown in FIG. 4 can be used to expand the 2.247′′ diameter container to a 2.363′′ diameter container.
- the expansion die shown in FIG. 5 can be used to expand the 2.363′′ diameter container to a 2.479′′ diameter container.
- the expansion die shown in FIG. 6 can be used to expand the 2.479′′ diameter container to a 2.595′′ diameter container. It should be noted that as the diameter of the container expands, the container height also becomes shorter.
- the die of FIG. 7 is the lower body profile setting die.
- the final expansion die may also be the lower body profile setting die.
- the lower body profile setting die may be used to produce the desired dimensions and features for the final container base profile. These features establish performance characteristics such as axial load, dome reversal, mobility and stacking.
- a method other than using a lower body profile setting die may be used to produce the desired dimensions and features for the final container lower body profile, such as base profile reforming or profiling. Any suitable lower body profile setting method may be used.
- the containers of FIGS. 8-10 are comprised of 3104 aluminum alloy having a H19 temper and the sidewall thickness is about 0.0088′′.
- thin walled which may comprises thicknesses of ⁇ 0.0070′′, ⁇ 0.0060′′, ⁇ 0.0050′′, ⁇ 0.0040′′, ⁇ 0.0030′′, hard-temper (H19, H39) drawn and ironed aluminum cans varying amounts including expanding these containers greater than 8% in diameter, greater than 10%, greater than, 15%, and greater than 20%. Expanding to the same and different degrees containers having different sidewall thicknesses, tempers, materials, methods of manufacture and other properties is also within the scope of the invention.
Abstract
Description
Claims (35)
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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US11/768,267 US7954354B2 (en) | 2006-06-26 | 2007-06-26 | Method of manufacturing containers |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US11/474,581 US7934410B2 (en) | 2006-06-26 | 2006-06-26 | Expanding die and method of shaping containers |
US11/768,267 US7954354B2 (en) | 2006-06-26 | 2007-06-26 | Method of manufacturing containers |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
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US11/474,581 Continuation-In-Part US7934410B2 (en) | 2006-06-26 | 2006-06-26 | Expanding die and method of shaping containers |
Publications (2)
Publication Number | Publication Date |
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US20080022746A1 US20080022746A1 (en) | 2008-01-31 |
US7954354B2 true US7954354B2 (en) | 2011-06-07 |
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US11/474,581 Active 2027-02-07 US7934410B2 (en) | 2006-06-26 | 2006-06-26 | Expanding die and method of shaping containers |
US11/768,267 Active US7954354B2 (en) | 2006-06-26 | 2007-06-26 | Method of manufacturing containers |
US13/053,972 Active US8555692B2 (en) | 2006-06-26 | 2011-03-22 | Expanding die and method of shaping containers |
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US11/474,581 Active 2027-02-07 US7934410B2 (en) | 2006-06-26 | 2006-06-26 | Expanding die and method of shaping containers |
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US13/053,972 Active US8555692B2 (en) | 2006-06-26 | 2011-03-22 | Expanding die and method of shaping containers |
Country Status (22)
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US (3) | US7934410B2 (en) |
EP (3) | EP2359954B1 (en) |
JP (3) | JP2009541066A (en) |
KR (3) | KR101146188B1 (en) |
CN (3) | CN101479057B (en) |
AR (3) | AR061636A1 (en) |
AT (1) | ATE515338T1 (en) |
AU (2) | AU2007265347B2 (en) |
BR (3) | BRPI0722422A2 (en) |
CA (3) | CA2655908C (en) |
DK (3) | DK2359954T3 (en) |
EA (3) | EA018405B1 (en) |
EG (3) | EG26491A (en) |
ES (3) | ES2567037T3 (en) |
GT (2) | GT200800293AA (en) |
MX (2) | MX2008016070A (en) |
MY (4) | MY146903A (en) |
NZ (3) | NZ595069A (en) |
PL (3) | PL2035165T3 (en) |
PT (2) | PT2035165E (en) |
WO (2) | WO2008002741A1 (en) |
ZA (2) | ZA200900415B (en) |
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US20120043294A1 (en) * | 2010-08-20 | 2012-02-23 | Alcoa Inc. | Shaped metal container and method for making same |
WO2013096636A2 (en) | 2011-12-22 | 2013-06-27 | Alcoa Inc. | Method for expanding the diameter of a metal container |
WO2013142655A1 (en) | 2012-03-22 | 2013-09-26 | Alcoa Inc. | Heat sink for an electronic component |
WO2015035318A1 (en) | 2013-09-06 | 2015-03-12 | Ali Unal | Aluminum alloy products and methods for producing same |
USD739731S1 (en) | 2013-10-03 | 2015-09-29 | Anheuser-Busch, Llc | Metal beverage bottle |
USD739732S1 (en) | 2013-10-03 | 2015-09-29 | Anheuser-Busch, Llc | Metal beverage bottle |
US9327338B2 (en) | 2012-12-20 | 2016-05-03 | Alcoa Inc. | Knockout for use while necking a metal container, die system for necking a metal container and method of necking a metal container |
US9358604B2 (en) | 2014-06-12 | 2016-06-07 | Ball Corporation | System for compression relief shaping |
US10022773B2 (en) | 2014-04-30 | 2018-07-17 | Alcoa Usa Corp. | Aluminum sheet with enhanced formability and an aluminum container made from aluminum sheet |
USD962702S1 (en) | 2020-06-19 | 2022-09-06 | Silgan Containers Llc | Stackable, thin-metal cup |
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US7726165B2 (en) * | 2006-05-16 | 2010-06-01 | Alcoa Inc. | Manufacturing process to produce a necked container |
US7934410B2 (en) * | 2006-06-26 | 2011-05-03 | Alcoa Inc. | Expanding die and method of shaping containers |
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